Transcript Section 6.D - Composite Panel Fabrication

GLAST LAT Project
March 24, 2003
GLAST Large Area Telescope:
Gamma-ray Large
Area Space
Telescope
Tracker Subsystem
WBS 4.1.4
6D: Composite Panel Fabrication
Thomas Borden
Stanford Linear Accelerator Center
Tracker Subsystem Engineer
[email protected]
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Agenda
•
•
•
•
•
•
•
Facilities
Tray Description and Types
Manufacturing Flow Plan
Tooling
Quality Assurance
Trays Production and EM Results
Conclusions
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Facilities
• Plyform SpA, Varolo Pombia; Prime Contractor to INFN for Tray Fabrication
and Assembly,
– Subcontractor for closeout machining
– Subcontractor for insert machining
• INFN Pisa; ESPI Test of bare panels
– Holographic test
– System can detect de-lamination defects in face sheets, between face
sheet and honeycomb and between face sheets and closeouts
• Centrotecnica, Milan; Tray vibration testing of panels with bias circuits and
Carbontungsten
Fiber Wall
– Qualification levels
– Verification of fundamental frequency
– Workmanship
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Tracker Mid Tray
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Tray Types
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Tray Type
Honeycomb
Core
Face sheet
Plies
Tungsten
Converter
MID
1 lb/ft3
4
3% Xo
LIGHT
1 lb/ft3
4
NO
HEAVY
3 lb/ft3
6
18% Xo
TOP
1 lb/ft3
4
3% Xo
BOTTOM
3 lb/ft3
6
NO
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Manufacturing Plan
Machine Closeouts
(outside Vendor)
Production Flow Diagram
Incoming Material
receiving
Inspection ref I.L.
02-105
Dimensional
Verification of
Closeouts
Face Sheet Lay-up
ref I.L. 02-106
Install Inserts ref
I.L. 02-117 &
I.L. 02-118
Assembly of Face Sheet with
Honeycomb with Redux 312 UL
Dimensional
Verification of
inserts
Assembly of Face
Sheet/Honeycomb and
Closeouts ref I.L. 02-118
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Dimensional Verification
and ESPI Testing
(workmanship)
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Manufacturing Plan
Production Flow Diagram Cont.
Final Trimming and
Cleaning Ref I.L. 02-116
Final Dimensional
Verification, weighing
and QA
Assembly of Bias
Circuits to Panel
Ref I.L. 02-118
Workmanship Vibration
Testing at
Centrotechnica
Assembly of
Tungsten to Panel
Ref I.L. 02-118
Ship to INFN
Ref I.L. 02-119
All assembly processes per LAT-PS-01584
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Tooling
• All assembly tooling documented and released
• All assembly tooling, and procedures, “proof tested” with EM
hardware
• Additional copies of “standard” tray tooling in production
• Sufficient tools available to support production rate of 10 standard, 4
thick, one top and one bottom tray(s) a week
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Tooling
Tray assembly bottom plate
Tray assembly top plate
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Tooling
Closeout bars
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Tooling
Closeout Insert
Assembly Tool
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Quality Assurance
• All processes controlled by ISO approved procedures at Plyform (I.L.
02-111, I.L. 02-112, I.L. 02-113)
• Regular INFN-Pisa oversight at Plyform
• Data Base Developed
• Nonconformance Reporting
– Plyform nonconformance reporting system per I.L. 02– LAT-PS-01584 specifies the following major Nonconformance
reporting limits require halting production:
• Rejection during dimensional inspection of more than 4 of the
trays produced out of a continuous sample of 40 trays.
• Rejection during dynamical tests of more than 4 of the trays
produced out of a continuous sample of 40 trays.
• Accidents resulting in irreparable physical damage (serious
enough for tray rejection) to more than 2 of the trays produced
out of a continuous series of 40 trays.
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Data Base
Main form:
• select tray type
• access all tray data
Tray data sheet:
• assembly data
• bare panel measurements
• final tray measurements (TBD)
• subcomponents IDs and data
• click on buttons to access details
Luca Latronico – INFN Pisa
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Data Base continued
Bare panel dimensions
(after clicking on
dimensions button):
• plots measurements of
reference points along
tray structure
• plots sides BD/AC
• flatness, orthogonality,
parallelism seen by
moving slide bar
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Luca Latronico – INFN Pisa
Luca Latronico – INFN Pisa`
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Data Base continued
Each submask containing detail measurements data and has a clickable legend
for reference – MCM legend shown here for example
Luca Latronico – INFN Pisa
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Data Base continued
Connected to Ladders DB –
this mask tracks ladders IDs,
location and currents (preencapsulation and postencapsulation) as measured
at G&A/Mipot.
Location/names given
according to LAT-TD-00376
convention, e.g.:
F – Front Side
B - Back Side
0 - connected to FE 0 side
….
3 – connected to FE 23 side
Luca Latronico – INFN Pisa
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GLAST:Gamma Ray Large Area Telescope
Trays Production
&
E.M. Results
R. Bagagli
INFN - sez. Pisa
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E.M. Tray Production
Tray name
Face sheet
honeycomb
Tungsten
Top
4 plies
1lb/ft3
3%Xo
Mid
4 plies
1lb/ft3
3%Xo
Light
4 plies
1lb/ft3
//
Heavy
6 plies
3lb/ft3
18%Xo
Bottom
6 plies
3lb/ft3
//
Defective
4 plies
1lb/ft3
//
N° trays delivered
Top tray
Mid Tray
Light Tray
Heavy Tray
Bottom Tray
Def. Tray
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Total
E.M. Tower
Mini Tower
N.D.I. Tests
ESPI
//
14
2
5
//
1
W.P.
11
2
4
W.P.
//
//
3
//
1
//
//
//
//
//
//
//
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E.M. Results: ASSEMBLING IMPROVEMENTS
1) Dimensional Check procedure on
the tool:
- measure the tool in six points with a caliber
- fill a form to compare the reference values
with the measured values
- If measured values are otuside ±0.03mm,
then the operator has to adjust the lateral wall
and to check again the value
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E.M. Results: ASSEMBLING IMPROVEMENTS
Glue-line on the sandwich with dispenser on the bonding area
(to avoid no-bonding area)
Vacuum bag at standard temperature
(to avoid air inclusion)
-The glue fills all the bonding area
- The exceeding quantity goes out
and will be removed in Refining
Step
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Tray assembly tools
tool
In house
Under
construction
total
assembly tool
3
4
7
Tungsten tool
2
1
3
Kapton tool
1
1
2
Trimming tool
1
0
1
Tungsten assembly tool
Tray assembly tool
Tray assembly rate capability: 3 trays/day
Upper plate
Reference wall
Trimming tool
Lower plate
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Skin
Tray
Tracker Peer Review, WBS 4.1.4
Kapton assembly tool
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E.M. Results: DIMENSIONS
trays DIMENSIONS
Structural SIDE: mean = 368.56mm, = 0.04mm
MCM SIDE: mean = 368.52mm, = 0.03mm
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Structural SIDE
18
MCM SIDE
16
14
12
10
8
6
4
2
0
368.40
368.50
368.60
368.70
mm
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E.M. Results: FLATNESS
Measured Surface
MID TRAYS FLATNESS: TOP FACE & BOTTOM FACE
Geometrical
Tolerances
TOP FACE
6
BOTTOM FACE
5
SIDE A
4
SIDE B
3
SIDE C
2
SIDE D
1
TOP FACE
SIDE A
TOP FACE
SIDE B
0
0
25
50
75
m
TOP FACE
SIDE C
TOP FACE
SIDE D
BOTTOM FACE
SIDE A
BOTTOM FACE
SIDE B
BOTTOM FACE
SIDE C
BOTTOM FACE
SIDE D
SIDE B
SIDE A
SIDE B
SIDE C
6
SIDE D
SIDE A
4
SIDE D
SIDE C
SIDE B
SIDE D
SIDE A
SIDE C
MID TRAYS FLATNESS: CLOSEOUTS
12
10
8
2
0
TOP FACE
BOTTOM FACE
6D
0
25
50
75
100
m
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E.M. Results: ORTHOGONALITY & PARALLELISM
Measured Surface
MID TRAYS ORTHOGONALITY
Geometrical
Tolerances
TOP FACE
30
BOTTOM FACE
25
SIDE A
20
SIDE B
15
SIDE C
10
SIDE D
TOP FACE
SIDE A
TOP FACE
SIDE B
TOP FACE
SIDE C
TOP FACE
SIDE D
BOTTOM FACE
SIDE A
BOTTOM FACE
SIDE B
BOTTOM FACE
SIDE C
BOTTOM FACE
SIDE D
SIDE B
SIDE A
SIDE B
SIDE C
SIDE D
SIDE A
SIDE D
SIDE C
SIDE B
SIDE D
SIDE A
SIDE C
5
0
0
25
50
75
m
MID TRAYS PARALLELISM
mean = 73 m
7
6
TOP FACE
BOTTOM FACE
6D
5
4
3
2
1
0
0
25
50
75
100
m
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E.M. Results: TRAY DATABASE
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Tests
Acceptance Tests
Facesheets
Production
ASTM D 3529
Resin content
v
ASTM D 3776
Fiber Areal Weight
v
ASTM D 3039
Tensil Stenght
v
ASTM D 4065
Glass Transition
Temperature dry
v
ASTM D 2344
Short Beam Shear
Strenght
v
C.M.M.
Geometrical Test
ASTM D 100299
Peel Strenght
N.D.I. Test
E.S.P.I. System
Closeout
machined
Closeout
Inserts
bonded
v
v
Sandwich
Bare Panel
Assembling
Kapton
Bonding
v
v
v
v
Tray without
Si detectors
v
v
v
v
v
Vibration Test
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Tungsten
Bonding
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Bare Panel: N.D.I. Test
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Bare Panel: N.D.I. Test
ESPI: Thermal Loads very effective
to detect bare panel defects
Skin-closeout debonding
Honeycomb crash
Honeycomb – Skin
debonding
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TG07: Bare Panel + W + Bias Plane
ESPI: Vibration TEST
817Hz first
resonance
mode
1860Hz second
resonance
mode
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Conclusions
•
•
•
•
All documentation in place.
Database in place.
Production Readiness Review scheduled for April 15, 2003.
All tray materials needed are delivered or on order and will be
available before need date.
• Tray production will begin on May 1, 2003
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